Methods and systems for preparation of a phosphate modified zeolite catalyst

A system of preparing a high value chemical product using a modified HZSM-5 zeolite catalyst, the system comprising:

• a milling unit equipped to receive a HZSM-5 zeolite powder and operated to produce a milled HZSM-5 zeolite powder with a particle size of less than about 2 microns;
• a first mixing unit equipped to receive the milled HZSM-5 zeolite powder, an aqueous alkaline solution, and a first phosphatation agent in a first predetermined amount, the first mixing unit being operated to mix the milled HZSM-5 zeolite powder, the aqueous alkaline solution, and the first phosphatation agent to produce a first phosphate treated AT-HZSM-5 zeolite containing about 5 weight percent of phosphorous pentoxide;
• a second mixing unit equipped to receive a clay powder and a deionized water and operated to mix the clay powder and the deionized water to produce an aqueous clay slurry;
• a third mixing unit equipped to receive an alumina powder and an aqueous acidic solution and operated to mix the alumina powder and the aqueous acidic solution to produce an alumina dispersion;
• a fourth mixing unit equipped to receive the clay slurry and the alumina dispersion and operated to mix the clay slurry and the alumina dispersion to produce a mixed binder slurry;
• a fifth mixing unit equipped to receive the first phosphate treated AT-HZSM-5 zeolite, the mixed binder slurry, and a second phosphatation agent in a second predetermined amount, the fifth mixing unit being operated to mix the first phosphate treated AT-HZSM-5 zeolite, the mixed binder slurry, and the second phosphatation agent to produce a second phosphate treated AT-HZSM-5 zeolite containing about 10 weight percent of phosphorous pentoxide;
• a sixth mixing unit equipped with an agitator to receive the second phosphate treated AT-HZSM-5 zeolite and operated to produce a homogenized zeolite slurry;
• a spray dryer equipped to receive the homogenized zeolite slurry and operated to produce spherical particles of a modified HZSM-5 zeolite catalyst;
• and
• a fluid catalyst cracking unit equipped to receive the modified HZSM-5 zeolite catalyst from the spray dryer and a hydrocarbon fluid containing a plurality of hydrocarbons to produce a high value chemical product containing ethylene, propylene, butene, benzene, toluene, and xylene, each hydrocarbon of the plurality of hydrocarbons containing less than about 24 carbon atoms.

A fluid catalytic cracking catalyst, comprising:

• a mesoporous HZSM-5 zeolite in an amount ranging from about 20 wt. % to about 55 wt. % f the fluid catalytic cracking catalyst, the mesoporous HZSM-5 zeolite containing about 10 wt. % f phosphorous pentoxide;
• a phosphorous oxide in an amount ranging from about 5 wt. % to about 15 wt. % P2O5 of the fluid catalytic cracking catalyst;
• an alumina binder in an amount ranging from about 20 wt. % to about 30 wt. % f the fluid catalytic cracking catalyst;
• a clay in an amount ranging from about 30 wt. % to about 40 wt. % f the fluid catalytic cracking catalyst;
• and
• a sodium ion in an amount greater than about 0.1 wt. % f the fluid catalytic cracking catalyst.